Basic Engine, V6: Overview Saab 9-5 I рестайлинг

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1. Position the car on a lift and drape the wings with protective covers. Raise the car slightly until the wheels are clear of the floor.
2. Reduce the fuel pressure by removing the fuel pump fuse while the engine is running. Switch off the ignition when the engine has stopped and refit the fuse.
3. Place the wheels in the straight ahead position and unbolt the steering column from the steering gear inside the cabin.
4. Remove the engine cover and battery cover.
5. Disconnect the battery cables and remove the battery.
6. Remove the battery tray and detach the wiring harness fasteners from the battery tray.
7. Unplug the connectors from the automatic transmission's wiring harness.
8. Remove the front wheels and hub nuts. Unscrew the ground cable, which is connected to the gearbox casing, in the left-hand wheel housing.
9. Remove the ground cable from the gearbox.
10. Withdraw the gearbox venting hose.
11. Detach the selector lever cable from the gear actuator and move the cable aside.
12. Disconnect the positive cable from the junction terminal and its fasteners on the main fuse board.
13. Detach the throttle cable from the throttle body and retaining bracket. Bend aside.
14. Remove the turbo pressure hose from the throttle body.
15. Unplug the connectors from the turbo pressure sensor and the intake air temperature sensor and disconnect the ground cable from the turbo pressure hose's connecting pipe.
16. Raise the car additionally. Detach the turbo pressure hose from the charge air cooler. Remove the lower spoiler sections.
17. Remove the air cleaner's rubber mounts from the subframe.
18. Insert two «83 95 238»(ref-212208-S14859113752005122300000) Wedges, between the oil sump and subframe and between the gearbox and subframe.
19. Detach the rear heated oxygen sensor's wiring from its attachments in the floor (certain models).
20. Separate the front exhaust system after the catalytic converter.
21. Detach the anti-roll bar link rods at the link arms.
22. Undo the outer tie-rod ends from the suspension struts. Use «89 96 696 PULLER»(ref-212208-S27822859612005122300000) .
23. Unscrew the lower steering swivel joint bolts from the link arms.
24. Place a receptacle under the car and open the radiator's drain cock.
25. Lower the car and unscrew the expansion tank filler cap.
26. Detach the vacuum hose from the charge air bypass valve and remove the turbo pressure hose together with the bypass pipe, valve and connecting pipe.
27. Remove the heat shield from the front exhaust manifold.
28. Detach the crankcase breather pipe from the turbo intake pipe. Collect the sealing washers.
29. Unplug the connector and remove the mass air flow sensor and intake hose. Disconnect the venting hose's quick-release coupling and remove the turbo's intake pipe.
30. Unplug the connectors and remove the radiator fan.
31. Remove the wiper arms, using special tool «85 80 144 PULLER WINDSCREEN WIPER ARM»(ref-212225-S39192933172005122200000) , and the windscreen cover.
32. Remove the engine control module's rubber seal and its connector.
33. Remove the cover over the engine wiring harness connector on the bulkhead. Separate the connector and remove the wiring with holder and place it on the engine.
34. Detach the vacuum hose from the heater system's shut-off valve.
35. Detach the brake servo's vacuum hose from the intake pipe connection by moving the red part of the hose in towards the intake pipe and pulling it outwards.
36. Detach the venting hose from the throttle body.
37. Undo the fuel rail connections. Have an absorbent cloth or paper handy to catch any fuel spillage. Carefully bend the hoses aside.
38. Detach the power steering oil reservoir from its bracket and undo the cable tie securing the hydraulic hoses. Fix the reservoir with hoses to the engine. Make sure that no oil leaks out of the reservoir's ventilation hole.
39. Detach the upper and lower radiator hoses and the hoses connected to the expansion tank and radiator.
40. Detach the automatic transmission's hydraulic hoses. Place a receptacle underneath. Fit a plastic bag or the like over the hose connections. Plug the oil cooler connections.
41. Remove the radiator.
42. Undo the hose connections for the cabin heat exchanger. Note the location of the hoses for subsequent assembly.
43. Remove the hose between the turbo's outlet and the charge air cooler.
44. Remove the front grille.
45. Secure the charge air cooler and the condenser with a «83 95 212»(ref-212208-S05469684072005122300000) Cable tie
46. Unplug the A/C compressor's connector.
47. Attach and pull down a «83 95 212»(ref-212208-S05469684072005122300000) Cable tie, which is to be used later to secure the AC compressor.
48. Detach the A/C pipes from the attachment points on the subframe.
49. Release the multigroove belt from tension and remove the right-hand engine mount with attachment and bracket.
50. Undo and remove the left-hand engine mount.
51. Check to make sure that everything has been detached and moved asidN "SQUREBOX" hat no damage will occur when the engine is removed.
52. Raise the car and place the «83 95 311»(ref-212208-S01556804312005122300000) Lifting trolley with lifting table under the power train. The height adjustments on the fixture should be in the lowest position.
53. Raise the lifting table and adjust it according to the locating points on the car body and fixture. Continue raising the lifting table until it touches the subframe. Raise it a little more and then adjust its height until it abuts evenly against the subframe.
54. Undo the subframe retaining bolts and the triangular stiffeners.
55. Carefully lower the power unit slightly, remove the drive shafts from the hubs and make sure that the generator's cooling duct has come away from its connection.
56. Remove the A/C compressor retaining bolts. Lift out the compressor and secure it with the previously mounted cable tie.
57. Lower the power unit additionally. Take care to ensure that nothing catches on it and that nothing has been left in place which could be damaged when the engine is removed.

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1. Run the lifting trolley with power train under the raised car.
2. Lower the car with care and raise the lifting table.
3. Remove the cable tie suspending the A/C compressor. Fit the A/C compressor retaining bolts and tighten them.
4. Fit the drive shafts in the hubs and connect the generator's cooling air duct.
5. Fit the subframe retaining bolts and the triangular stiffeners. Tightening torque: Subframe 100 Nm + 45° (74 lbf ft + 45°)
6. Fit the left-hand engine mount.
7. Lower the car. Fit the multigroove belt. Fit the right-hand engine mount with attachment and bracket.
8. Fit the A/C pipes to the attachment points on the subframe.
9. Remove the cable tie suspending the charge air cooler and condenser.
10. Refit the front grille. IMPORTANT: To reduce the risk of hoses mounted on the delivery side of the turbocharger coming loose due to low friction at high air pressures, the hoses and connecting pieces must be cleaned thoroughly before fitting. Use a rag dampened with 93 160 907 Motip Dupli cleaning agent to wipe clean inside the ends of the hoses. Clean also the connecting pieces. If hose clips are rusty or damaged, they must be replaced with new ones to maintain the correct clamping force.
11. Fit the hose between the turbo outlet and charge air cooler.
12. Plug in the A/C compressor connector.
13. Fit the radiator.
14. Remove the plugs from the oil cooler connections. Connect the automatic transmission's hydraulic hoses.
15. Connect the upper and lower radiator hoses as well as the expansion tank and radiator hoses.
16. Connect the hoses for the cabin heat exchanger. 16.1. Do not mix up the hoses. Connect as follows: A - expansion tank, B - shutoff valve, and C - heat exchanger.
17. Fit the power steering oil reservoir. Secure the hydraulic hoses with a cable tie.
18. Connect the fuel lines.
19. Connect the venting hose to the throttle body.
20. Connect the vacuum hose for the brake servo to the intake manifold connection.
21. Connect the vacuum hose to the heater system's shut-off valve.
22. Fit the wiring harness with holder and plug in the connector. Fit the cover over the engine wiring harness connector on the bulkhead.
23. Plug in the engine control module connector and fit the rubber seal.
24. Fit the wiper arms and windscreen cover.
25. Fit the radiator fan and plug in the connectors. Tightening torque: 8 Nm (6 lbf ft)
26. Fit the turbo intake pipe, intake hose and mass air flow sensor. Reconnect the venting hose and plug in the mass air flow sensor's connector. Tightening torque: V-clamp 3 Nm (2 lbf ft) U-clamp cylinder head 14 Nm (10 lbf ft)
27. Fit the crankcase breather pipe to the turbo intake pipe. Tightening torque: 24 Nm (18 lbf ft)
28. Fit the heat shield to the front exhaust manifold. Tightening torque: 24 Nm (18 lbf ft)
29. Fit the turbo pressure hose together with the charge air bypass pipe, valve and connecting pipe. Connect the vacuum hose to the charge air bypass valve. Tightening torque: Bypass pipe 8 Nm (6 lbf ft)
30. Raise the car and fit the lower steering swivel joint bolts. Tightening torque, lower bolts 30 Nm + 90° (22 lbf ft + 90°) Tightening torque, bolt on steering swivel member 60 Nm + 90° (44 lbf ft + 90°)
31. Fit the link rods to the anti-roll bar. Hold with a open wrench or hold the hexagonal pin with a socket. Tightening torque: 84 Nm (62 lbf ft) Tightening torque, nut with steel lock: 95 Nm (66 lbf ft)
32. Fit the outer track-rod ends to the suspension struts.
33. Fit the front exhaust system. Tightening torque: 22 Nm (16 lbf ft).
34. Fit the air cleaner's rubber mounts to the subframe.
35. Secure the rear heated oxygen sensor's wiring to the floor (certain models).
36. Refit the lower spoiler sections. Connect the turbo pressure hose to the charge air cooler.
37. Plug in the connectors for the turbo pressure sensor, intake air temperature sensor and ground cable for the turbo pressure hose's connecting pipe.
38. Lower the car and fit the turbo pressure hose to the throttle body.
39. Refit the throttle cable.
40. Connect the positive cable to the junction terminal. Secure the cable to the main fuse board.
41. Fit the selector lever cable to the gear actuator. Tightening torque: 20 Nm (15 lbf ft)
42. Connect the ground cable to the gearbox. Fit the gearbox venting hose.
43. Connect the ground cable to the left-hand wheel housing. Fit the front wheels and hub centre nuts. Tightening torque: Wheel: 110 Nm (81 lbf ft) Hub centre-nut 290 Nm (214 lbf ft) Hub centre-nut with top groove 170 Nm +45° (170 lbf ft + 45°)
44. Move the battery tray sideways away from the engine as far as possible. Fit the battery tray. Secure the wiring harness to the battery tray.
45. Fit the battery and connect the battery cables.
46. Fit the battery cover and engine cover.
47. Plug the connectors into the automatic transmission wiring harness. Remove the protective covers from the wings.
48. Bolt the steering column to the steering gear inside the cabin. Tightening torque: 25 Nm (18.5 Nm)
49. Fill the radiator with coolant and check the system for leaks.
50. Bleed the cooling system as follows: Fill the system up to the MAX level, close the expansion tank filler cap, start the engine and warm it up (by running it at varying rpm) until the radiator fan starts. Unscrew the expansion tank filler cap and top up again to the MAX level. Close the filler cap and run the engine at varying rpm until the radiator fan starts three more times. Switch off the engine and top up as necessary to the MAX level. NOTE: The A/C should be OFF.
51. Drive the car on test and check all functions. Also check the engine oil level and gearbox oil level (or transmission fluid level).
52. Reset the clock and the radio, if fitted.

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1. Drape wing protectors over the wings.
2. Position a jack under the oil sump, using a wooden block or the like between sump and jack, and take the weight of the engine off the engine mounting.
3. Mark the position of the engine mounting on its yoke with a cross.
4. Remove the engine mounting's yoke. IMPORTANT: Since the retaining yoke's bolts are screwed into aluminium, it is easy to damage the threads in the metal.
5. Remove the engine mounting.

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1. Fit the engine mounting. Tightening torque: 63 Nm (46.5 lbf ft)
2. Fit the yoke, centre the engine mounting in the yoke as marked, lower the engine and check that it hangs neutrally by shaking it.
3. Tighten the engine mounting's retaining nuts, using a torque wrench. Tightening torque: 105 Nm (77.5 lbf ft)
4. Remove the jack and wing protectors.

Scheme 461

1. Drape wing protectors over the wings and remove the cover over the battery.
2. Disconnect the battery cables, remove the battery and its tray.
3. Position a jack under the gearbox and take the weight off the engine mounting.
4. Mark the position of the engine mounting in the bracket to retain the engine's centring.
5. Remove the engine mounting.

Scheme 462

1. Check that the engine is at the right level. Fit the engine mounting loosely as marked
2. Lower the jack and remove it.
3. Check that the engine hangs neutrally and tighten the engine mounting, using a torque wrench. Tightening torque: To body 63 Nm (46.5 lbf ft) To engine mount 84 Nm (62 lbf ft)
4. Move the battery tray sideways away from the engine as far as possible. Fit the battery and tray.
5. Connect the battery cables and fit the cover in place.
6. Remove the wing protectors. Reset the clock and the radio, if fitted.

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1. Drape wing protectors over the wings and remove the engine cover.
2. Remove the front exhaust manifold's heat shield.
3. Unbolt the front pipe from the turbo.
4. Unplug the oxygen sensor's connector.
5. Fit the front and rear lifting eyes (included in holder part No. «83 95 287 Holder»(ref-212208-S38456750642005122300000) ). The rear lifting eye fits on the rear of the rear cylinder head while the front lifting eye is fitted by undoing the water pipe's retaining bolt, on the side of the front cylinder head, sufficiently to allow the lifting eye to be hooked on it. Fit the holder (included in holder, part No. 83 95 287), and «83 94 850»(ref-212208-S21175326122005122300000) Lifting beam and raise the engine.
6. Remove the engine mounting's upper locknut and its subframe retaining bolts.
7. Raise the car.
8. Snip the cable tie securing the oxygen sensor cable. Note the way the cable is run and lower the cable.
9. Separate the pipe joint between the front and rear exhaust systems. NOTE: To ease disassembly of the front exhaust system, attach a «83 95 212»(ref-212208-S05469684072005122300000) Cable tie around the front pipe.
10. Detach the front exhaust pipe from the rear exhaust manifold and lower away the front exhaust system.
11. Unbolt the engine mounting's upper bracket from the gearbox. Remove the bracket downwards.
12. Remove the engine mounting with lower bracket. Remove the engine mounting downwards.
13. Unbolt the engine mounting from the lower bracket.

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1. Bolt the engine mounting to its lower bracket and fit the cable.
2. Insert the rear retaining bolt and position the engine mounting. Screw in the rear bolt a turn or two and then insert the two front retaining bolts.
3. Bolt the upper bracket to the gearbox. Tightening torque: 84 Nm (62 lbf ft)
4. Fit the front exhaust pipe to the rear exhaust manifold. Tightening torque: 40 Nm (29.5 lbf ft) NOTE: To ease assembly of the front exhaust system, attach a «83 95 212»(ref-212208-S05469684072005122300000) Cable tie around the front pipe.
5. Fit the pipe joint between the front and rear exhaust systems. Tightening torque: 22 Nm (16 lbf ft).
6. Use a cable tie to secure the oxygen sensor cable. Carefully run the cable back to the oxygen sensor connector.
7. Lower the car.
8. Plug in the heated oxygen sensor's connector.
9. Bolt the front exhaust pipe to the turbo. Tightening torque: 24 Nm (17 lbf ft)
10. Fit the front exhaust manifold's heat shield. Tightening torque: 24 Nm (18 lbf ft)
11. Check the position of the engine mounting and its cable.
12. Lower the engine and remove the lifting beam, holder and lifting eyes. Tighten the water pipe bracket's retaining bolt on the side of the front cylinder head. Tightening torque: Cylinder head retaining bolt 14 Nm (10 lbf ft)
13. Tighten the engine mounting's retaining bolts, using a torque wrench. Tightening torque: 26 Nm (19 lbf ft)
14. Fit the engine mounting's upper retaining nut. Tightening torque: 47 Nm (35 lbf ft)
15. Fit the engine cover and remove the wing protectors.

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1. Remove the bracket for the engine wiring harness.
2. Remove the support bearing bracket with pipe and inboard drive shaft universal joint.
3. Disconnect the starter motor and remove same.
4. Remove the plastic plug under the starter motor and remove the torque converter bolts. Advance the torque converter gradually by turning the crankshaft with the pulley.
5. Prevent the torque converter from moving by means of «87 92 574 HOLDER»(ref-212208-S24045042792005122300000) .
6. Remove the gearbox.
7. Remove the front exhaust pipe with heated oxygen sensor, power steering pump and power unit from the subframe.
8. Fit Holder part no. 83 94 751 to the power train and lift over the power train to «78 74 878 FLOOR STAND»(ref-212208-S36366567092005122300000) .
9. Remove the belt tensioner and disconnect and remove the generator. Do not forget to remove the lead to the oil pressure sensor from the generator.
10. Detach the vacuum hose and water hoses from the throttle. Also unplug the throttle's connector.
11. Detach the temperature sensor on the coolant bridge.
12. Remove the upper intake manifold.
13. Disconnect the leads to the injectors. Remove the middle intake manifold.
14. Remove the lower intake manifold. Plug the induction orifices.
15. Disconnect the lead to the oil pressure sensor.
16. Drain the oil and tighten the drain plug. Tightening torque: 25 Nm (18.5 lbf ft).
17. Remove the dipstick.
18. Remove the turbo's water and oil pipes.
19. Remove the turbo's bracket.
20. Remove the crankshaft position sensor.
21. Remove the oil filter and the oil pipes from the oil filter adapter.
22. Remove the rear exhaust manifold's heat shield. Remove the rear exhaust manifold.
23. Remove the front exhaust manifold.
24. Detach the coolant pipe and remove the thermostat housing with thermostat.
25. Remove the coolant bridge, being careful not to damage the gaskets.
26. Remove the crankcase breather housing.
27. Disconnect the leads to the ignition discharge modules and remove the engine wiring harness. Remove the ignition discharge modules.
28. Remove the spark plugs using Spark plug socket part no. «83 95 485 Spark plug socket assembly with locating sleeves»(ref-212208-S27104805752005122300000) , and also remove the camshaft covers with gaskets.
29. Remove the coolant pump pulley and crankshaft pulley.
30. Remove the timing cover.
31. Zero the engine. Mark the direction of rotation on the timing belt and undo the belt tensioner. Remove the timing belt. Rotate the crankshaft to 60° BTDC. WARNING: The camshafts must not be rotated as the valves may collide with the pistons or each other and be damaged. The crankshaft may be rotated only between 0° and 60° before top dead centre when the camshafts on both cylinder heads are secured with a locking tool.
32. Remove the bracket with tensioning roller and the upper adjuster roller.
33. Remove the lower adjuster roller.
34. Hold the camshafts with a spanner and remove the camshaft sprockets. WARNING: The jaws of the open-ended spanner used as a counterstay when removing the camshaft sprockets must not be too long. There is otherwise a risk of damaging the metal so that the tappets become locked .
35. Remove the coolant pump, taking care not to damage the O-ring. NOTE: There is quite a lot of coolant left in the engine so always place a receptacle under the engine to collect it.
36. Remove the inner timing cover.
37. Remove the exhaust camshaft bearing caps by undoing the bolts in steps of 1/2 to 1 turn. It is important to conclude removal at the bearing cap where the tappets are under load. Lift out the camshafts and remove the stuffing boxes. Note the marking on the camshaft bearing caps. IMPORTANT: The camshafts must come away from the bearing seats evenly. NOTE: The intake camshafts can remain in place.
38. Remove the tappets and keep them in «83 93 787 VALVE STAND»(ref-212208-S09402876942005122300000) so that they are kept in order. Fit Protective collars part no. «83 95 022»(ref-212208-S27334477672005122300000) .
39. Undo the cylinder head bolts in the order shown in steps of 1/4 - 1/2 a turn. Remove the cylinder heads. Exercise care when putting them down as the intake camshafts are still in place and the valves could easily be bent through carelessness.
40. Detach the pipes from the heat exchanger, being careful with the gaskets. Remove the heat exchanger cover complete with the heat exchanger. IMPORTANT: Not the fitting position.
41. Mark the pistons with the cylinder number.
42. Turn the engine. Remove the oil sump, oil suction pipe and antislosh baffle.
43. Fit Counterstay «83 95 063»(ref-212208-S02545993922005122300000) and remove the camshaft belt sprocket from the crankshaft. Remove the oil pressure sensor.
44. Remove the oil pump and gasket.
45. Remove the front crankshaft seal.
46. Remove the drive plate. Carefully prise out the rear crankshaft seal. IMPORTANT: Do not damage the sealing surface.
47. Undo all big-end bearing caps and press or carefully tap the pistons out of the cylinders in pairs. Start with 1 and 2.
48. Remove the main bearing member by first undoing the middle bolts on the long sides and unscrewing the adjusting sleeves about 1/2 a turn. NOTE: If the adjusting sleeves are tight-fitting, they need not be unscrewed.
49. Remove the rest of the bolts. Note the position of the main bearing member for subsequent reassembly.
50. Remove all main bearing caps and lift out the crankshaft.
51. Remove the slotted ring. IMPORTANT: Observe the utmost care when handling the slotted ring.
52. Remove all bearing shells for both the main bearings and big-end bearings.

Description

The hydraulic engine mount consists of two chambers filled with a special damping fluid. Interposed between the two chambers are a diaphragm and a passage, the length and cross-sectional area of which determine the damping characteristics of the mount. The diaphragm absorbs the forces generated by the normal small movements of the engine.

If engine movement is more pronounced, the damping action of the diaphragm will be insufficient. Fluid is then forced from the upper into the lower chamber, equalizing the pressure. This gives the hydraulic mount a progressive damping action, which means that the resistance of the mount increases with increased load.